JP2010092851A - Electrical connection system for use on aluminum wires - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a connector which achieves solid electrical and mechanical connection and eliminates failure of a connection part caused by corrosion without damaging and breaking a wire and/or terminal. <P>SOLUTION: A connection mechanism includes a metal segment 100, which is mechanically and electrically communicated with remainder of the connection mechanism, on at least one side. The segment includes at least one tab 104 protruding from the segment on a first side. A plurality of metal deformations are provided in a central area of the segment. When the metal deformations are pressed into aluminum, they can pierce through corrosion product on a surface of the aluminum in order to make electrical contact with the aluminum. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The basis of many electrical technologies includes the ability to connect various electrical devices to each other. It is common to connect these electrical devices using several types of electrical cable assemblies, including electrical conductors (such as wires and coaxial cables) and conductive terminals coupled to at least one end of the electrical conductor. is there. The conductive terminals are typically “crimped” to the end of the conductor using a crimping tool. This re-forms the terminal around the conductor, forming a firm connection. The end of the crimped conductor is also called a connector. In use, a terminal is used to couple a conductor to an electrical device. In many cases, the reliability of an electrical device is determined in part by the quality of the connection formed between the terminal and the conductor (ie, crimping, in other words, crimping). Thus, caulking (crimping) not only provides an electrical connection, but also provides a mechanical connection to protect against torsional and tensile forces. Such forces can damage the terminals or wires and break the electrical connection.

  Known crimp type connectors use only crimping forces or pressures to electrically and mechanically connect between terminals and wires. However, this force tends to damage or break either the wire or the terminal. Using a relatively small crimp force to prevent damage or breakage may make the electrical or mechanical connection unsuitable for the needs of the system. Furthermore, using pressure contact methods to form an effective electrical connection between the terminal and the conductor is hindered by various corrosion products on the surface of the terminal and conductor. Various methods have been used to solve these obstacles, but few of these have been successfully mass produced.

  Another consideration is to form a stable electrical connection over a long period of time and against many different environmental factors. This often requires that the initial mechanical connection can resolve both wire and terminal surface corrosion. This type of connection is particularly difficult when using aluminum wires. This is because the hardness of aluminum is low and the corrosion products formed on the aluminum are much harder than the aluminum itself.

  Thus, there is a need for a connector that can eliminate damaging connections and provide robust electrical and mechanical connections without damaging or destroying wires and / or terminals.

  The coupling mechanism includes a metal segment. The metal segment is mechanically and electrically connected at least one side to the rest of the connection mechanism. In the central region of the segment, at least one tab protrudes from each side of the segment. At least a plurality of metal deformation portions are provided in the central region, and these deformation portions are electrically connected to aluminum when pressed against aluminum, so that corrosion of the surface of aluminum can be penetrated.

FIG. 1A is a view showing a connector segment for crimping a wire around a wire having a knurled metal area and having one tab on each side. FIG. 1B shows a connector segment for caulking (crimping) around the wire with a ridge-like metal area and one tab on each side. FIG. 1C shows a connector segment wrapped around a wire with one tab on each side. FIG. 2A is a diagram showing a connector segment for crimping a wire around a wire having a knurled metal region and two tabs on each side. FIG. 2B shows a connector segment wrapped around a wire with two tabs on each side. FIG. 3A shows two tabs on each side that are wrapped around the wire and separated by a notch so that the two tabs are crimped (crimped) with different levels of force. FIG. 6 is a view showing a connector segment. In FIG. 3B, there are two tabs on each side, these tabs are wrapped around the wire and the two tabs are crimped (crimped) with different levels of force to form a step. FIG. 6 is a view showing a connector segment.

  Examples of the connector for electrically and mechanically connecting to a conductor (that is, a wire, a cable, etc.) include a terminal provided with a deformed portion or a knurled line. This provides an electrical connection between the terminals when the terminals are crimped around the conductor (ie, crimped) despite the corrosion present on the conductors and / or terminals. The deformation further provides mechanical connection and strength when crimped (crimped) around the conductor. In one exemplary method, the terminal is further provided with a plurality of tabs with notches (notches) formed therebetween. These notches allow the conductor to be partially redistributed across the notch area during the crimping process. For soft metals, such as aluminum, where corrosion products are likely to form on the surface, the notch can apply more force during the crimping process than without the notch.

  FIG. 1A shows a portion of terminal 100 for caulking (ie, crimping) around a conductor. The segment 100 includes a metal region provided with knurled eyes, including a plurality of knurled eyes 106. The illustrated pattern of the knurled eyes 106 formed in a protruding shape is an example, and may have any desired pattern. Different patterns of knurled eyes 106 provide different electrical and / or mechanical coupling characteristics. The pattern of the knurled eyes 106 is not limited to the illustrated area, and the area may be expanded or decreased according to the needs of the application. The knurled eye 106 may be designed to be electrically and mechanically connected to the bare wire, or in another aspect it is connected by penetrating a coating on the wire surface, thereby making the wire It may be designed to come into contact with. Instead of the knurled eye 106, any other shape that provides the desired electrical and / or mechanical coupling characteristics may be used.

  Segment 100 includes one tab section 104 on each side. The illustrated size and shape tabs 104 are exemplary and may be adjusted according to wire diameter or other related parameters. The tabs 104 are shown to be mirror-symmetric with respect to each other about an axis that bisects the tip 102 disposed between the two sides. This is one exemplary embodiment and segment 100 is not limited to this description. A variation of segment 100 may be provided with tabs 104 that are very different from each other on the two sides of the segment.

  FIG. 1B shows a connector segment similar to that shown in FIG. 1A, wherein the connector segment is provided with knurled eyes 106 in a pattern of ridges (ie, elongated ridges or protrusions) 107. The number of ridges 107 may be selected according to associated parameters and is not limited to the number shown. Similarly, the dimensions and placement of the ridge 107 may be selected to meet the application needs.

  FIG. 1C shows the connector segment shown in FIGS. 1A and 1B after the exemplary caulking process has been performed on the segment. The tab 104 is bent around the wire 120 and pressed firmly against the wire 120. The tabs may only partially enclose the wire 120 and leave a gap between the crimped tabs 104. In another aspect, the tabs 104 may be largely wrapped around the wire 120 so that the tabs 104 abut or overlap each other. The caulking process may leave marks on tab 104 as shown by exemplary fold line 110. However, the caulking process may leave tabs 104 that are substantially free of such indicia.

  FIG. 2A shows another embodiment of a connector segment 200 for caulking around a wire. This segment 200 is similar to the connector segment 100 shown in FIG. 1A, except that the segment 200 has two tabs 204 with notches 208 in between. The width and shape of the notch 208 may be defined as desired. The tip (ie, end) 202 may terminate the segment 200 as shown, and may be electrically and mechanically connected to the rest of the coupling mechanism in any form suitable for the application. Also good. Knurls 206 may be provided over the area of segment 200 as necessary to provide proper electrical and mechanical connections. The knurled eye 206 may be of any type or pattern, or any other deformation that provides the desired electrical and mechanical connection may be used in place of the knurled eye.

  Segment 200 is an example for a connector segment having a plurality of tabs 204 and a corresponding number of notches 208. The number of tabs 204 can be a function of wire diameter, required mechanical coupling strength, desired electrical stability, and the like.

  FIG. 2B shows the connector segment 200 of FIG. 2A after performing an exemplary caulking process on the segment. The tab 204 is bent around the wire 220 and pressed firmly against the wire 220. The tabs 204 may be designed to only partially wrap around the wire 220 and leave a gap between the crimped tabs 204. In another aspect, the tabs 204 may be wrapped largely around the wire 220 so that they abut or overlap each other. The crimping process may leave a mark on tab 204 as shown by exemplary fold 210. However, the caulking process may leave tabs 204 that are substantially free of such indicia. The notch 208 between the tabs 204 allows the aluminum wire to be displaced when the aluminum wire is compressed by the tab 204, thus sufficient for the knurled eye 206 to make an electrical connection through the corrosion product layer on the wire. A force can be applied to the tab 204. By deforming the wire into the notch, it is possible to provide additional torsional strength to the connecting portion.

  FIG. 3A shows another novel feature of a connector segment having a plurality of tabs. The segment 300 which is one Example of segments, such as the segment 200, is shown with the perspective view seen from the side. Individual tab pairs 303 and 305 separated by notch 308 can each be crimped with different forces around the wire. The segment 300 is shown in a state after the caulking process is complete, in which the effective circumference of the tab 303 pair is larger than the tab 305 pair. This may be required when the force required for electrical connection is greater than the force required for mechanical connection. Because of the remaining shape of the coupling mechanism with respect to segment 300, some areas of segment 300 are more easily damaged than others. Due to a sufficiently large force for electrical connection, the material of the segment 300 may be subjected to stress leading to damage, for example, at the tab pair 303. Thus, for example, the tab pair 303 may be sufficiently crimped so that only mechanical connection is made, whereas the tab pair 305 is sufficient to make electrical connection in addition to mechanical connection. You may just squeeze it.

  Segment 300 is not limited to two tabs 303 and 305, but may include as many tabs and corresponding notches as required to meet the coupling mechanism specifications. Each of these tabs can be mechanically connected in stages by caulking with different forces. These steps may be ascending or descending, and in other embodiments may be any other pattern that rises and falls step by step.

  FIG. 3B shows one such stepped pattern including two tab pairs 353 and 355 with a very narrow notch disposed therebetween. Tab pair 355 is in the first stage of compression and tab pair 353 is in the second stage of compression. The second stage of compression uses a relatively small caulking force with the tab pair 353. There is a step 358 between the crimped tab pair 353 and the crimped tab pair 355.

  In all drawings, the tabs are shown in pairs. One tab on each of the two sides provided with tabs is aligned with each other for caulking. However, these tabs do not necessarily have to be aligned, and the two sides may not have the same number, size, or shape of tabs.

  The above description is intended to be illustrative and not limiting. Those skilled in the art will appreciate many alternative approaches or uses other than those described above upon reading the foregoing description. The scope of the invention should not be determined with reference to the above description, but should be determined with reference to the appended claims and the scope of all equivalents of those claims. Should. Future developments will occur in the technology discussed herein, and the disclosed systems and methods will be incorporated into such future examples. In short, it should be understood that the invention is capable of modification and variation and is limited only by the following claims.

  The above-described embodiments specifically illustrated and described are merely illustrative of the best mode. It will be understood that various changes to the embodiments described herein may be used in implementing the claims without departing from the spirit and scope as defined in the following claims. It should be understood by those skilled in the art. The following claims are intended to define the scope of the invention, and the methods and apparatus within the scope of these claims and their equivalents are included within the scope of the claims. This description should be understood to include all novel and non-obvious combinations of the elements described herein, and the claims of this and the subsequent application are intended to cover any of these elements. Provided for new and non-obvious combinations. Further, the above-described embodiments are exemplary, and there is no single feature or element important for all possible combinations claimed in this and subsequent applications.

  All terms used in the claims are given the broadest reasonable structure of the terms and their ordinary meaning as understood by one of ordinary skill in the art unless there are clear indications to the contrary. Specifically, one or more of the elements indicated in the singular, such as “above” or the like, unless it is explicitly stated in the claims that it is singular. Should be read as there is.

100 conductor segment 104 tab section 106 knurl 107 ridge 110 fold 120 wire

Claims (20)

A coupling mechanism,
A metal segment with at least one side mechanically and electrically connected to the rest of the connection mechanism;
At least one tab protruding from the first side of the segment;
A central region of the segment provided with a plurality of metal deformation portions,
The deformation mechanism is a coupling mechanism that can penetrate corrosion on the surface of aluminum because the deformable portion comes into electrical contact with aluminum when pushed into aluminum. The connection mechanism according to claim 1,
The connecting mechanism is configured such that the segment is caulked around an aluminum wire, whereby the connector and the wire can be electrically and mechanically connected. The connection mechanism according to claim 1,
The metal deformation portion is a knurling eye. The connection mechanism according to claim 3,
Each knurled eye is either a ridge or a protrusion that is small with respect to the size of the central region of the segment. The connection mechanism according to claim 1,
The at least one tab is a plurality of tabs provided with notches therebetween;
When the tab is firmly pushed into the aluminum, the aluminum expands and deforms to enter the notch and can be electrically connected. The connection mechanism according to claim 1,
The metal deformation portion extends into at least one tab. The connection mechanism according to claim 5,
The metal deformation portion extends into the plurality of tabs. The connection mechanism according to claim 1, further comprising:
A coupling mechanism comprising at least one tab protruding from the segment on a second side of the segment opposite the first side. The connection mechanism according to claim 1,
The metal deformable portion is a coupling mechanism, which is a sawtooth portion. A wire harness,
At least one wire,
A connector provided on one of the at least one wire,
The connector includes at least one segment;
Each segment of the at least one segment includes at least one tab crimped around the wire;
Each segment of the at least one segment has at least one side mechanically and / or electrically connected to the rest of the connection mechanism;
In the central region of the first segment of the at least one segment, a plurality of metal deformation portions are provided, and these metal deformation portions are in electrical contact with the wire. Wire harness that penetrates the corrosion on the surface of the wire. The wire harness according to claim 10,
The metal deformable portion is a wire harness that is a knurled eye. The wire harness according to claim 10,
The said metal deformation | transformation part is a wire harness which is a serrated part. The wire harness according to claim 10,
The wire harness is a wire harness that extends into the at least one tab. The wire harness according to claim 10,
The wire harness, wherein the at least one tab is a plurality of tabs provided with notches therebetween. The wire harness according to claim 14, wherein
The said metal deformation | transformation part is a wire harness extended in at least 1 tab of several tabs. The wire harness according to claim 14, wherein
A wire harness in which when the tab is firmly pushed into aluminum, the aluminum is deformed and enters the notch to be electrically connected. A method for caulking a connector around an aluminum wire,
Providing an aluminum wire to be crimped to each other and a metal segment of the connector, the segment comprising a region provided with a metal deformation that can penetrate corrosion on the wire;
Wrapping at least two tabs of the segment around the wire using a first tool;
Using the first tool or the second tool, sufficient to electrically connect at least a first portion of the at least two tabs of the segment to the wire and between the segment and the wire. Pressing with strong force,
Ensuring that the metallic deformation of the segment penetrates corrosion on the wire. The method of claim 17, further comprising:
The first tool, the second tool, or the third tool was used to press at least a second portion of the at least two tabs against the wire and the first portion against the wire. A method comprising the step of pressing with a force less than a force. The method of claim 17, wherein
The method, wherein the metallic deformation is a knurled or serrated portion. The method of claim 17, wherein
The method wherein the at least two tabs are a plurality of tabs provided on two sides of the segment.

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